Harley Davidson 2005 touring models. Service repair manual — page 10
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f2214x8x
CONNECTOR
DESCRIPTION
NUMBER
[A, C] = Pin
[B, D] = Socket
LEFT SIDE
[105A, 105B]
Interconnect to Nacelle Switch Harness
[105]
[105C, 105D]
Nacelle Switch Harness to Speaker Switch
Clutch
Cable Clip
RIGHT SIDE
Speaker
Switch [105D]
4-Place Multilock
Throttle
Cable Clip
Instrument Nacelle
Switches [105B]
12-Place Multilock
Speaker
Switch [105C]
4-Place Multilock
f2213x8x
Figure 2-169. Instrument Nacelle Halves
b. Slide spacer over threaded post of ignition switch
INNER FAIRING
housing until it contacts switch position plate. Slide
collar over post with the tab side down (and for-
ward). Install nut, and using a 7/8 inch wrench on
REMOVAL
flats, tighten to
50-70 in-lbs
(5.7-7.9 Nm). See
1.
Place protective material on top of front fender to protect
lower frame of Figure 2-168.
paint from scratches or other damage.
c. With the red arrow pointing toward the ACCESS
2.
Remove the outer fairing. See OUTER FAIRING,
position, install the ignition switch knob. Turn key
REMOVAL, in this section.
clockwise to UNLOCK position and then turn knob
3.
Carefully cut two cable straps to free wire bundles and
to OFF.
conduit from convoluted tubing of interconnect harness
and allow to hang naturally.
11. Install bezel. See BEZEL, INSTALLATION, in this sec-
4.
See Figure 2-170. Disconnect main harness from inter-
tion.
connect harness as follows:
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2005 Touring: Chassis
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Main to Interconnect
Harness [1]
Radio Antenna
Left Handlebar
Cable [51]
Switch Controls [24]
Right Handlebar
Switch Controls [22]
Main to Interconnect
Harness [156]
Radio
Ground
Main to Interconnect
Harness [2]
Right Turn
Left Turn
Signal [31R]
Signal [31L]
Headlamp [38]
Main to Interconnect
Harness [15]
Ignition
Switch [33]
f2269x8x
Figure 2-170. Inner Fairing Connections (FLTR)
● Main to interconnect harness connector [1], 12-
● Radio antenna cable connector [51]; back of radio
place Deutsch (black); below radio (right side).
(left side).
● Main to interconnect harness connector [2], 12-
place Deutsch (gray); below radio (right side).
6.
See Figure 2-170. Disconnect handlebar switch controls
from interconnect harness. Disconnect radio ground.
● Main to interconnect harness connector [15], 4-
Proceed as follows:
place Packard (black); below radio (right side).
● Main to interconnect harness connector [156], 6-
● Left handlebar switch controls connector [24], 12-
place Deutsch (gray); below radio (right side).
place Deutsch (gray); T-stud on left side of radio
bracket.
5. See Figure 2-170. Disconnect ignition switch from main
● Right handlebar switch controls connector [22], 12-
harness. Disconnect radio antenna cable. Proceed as
place Deutsch (black); T-stud on left side of radio
follows:
bracket.
● Ignition switch connector
[33],
4-place Packard
● Radio ground; single spade and socket terminal;
(black); inside fairing bracket tunnel (right side).
below radio (left side).
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15. Remove right side instrument nacelle. See INSTRU-
f2237x2x
MENT NACELLE, REMOVAL, in this section, steps 8-9.
16. Remove shop towels and masking tape from around the
harness bundle. Separate radio ground and main har-
ness, ignition switch and handlebar switch control con-
duit.
Interconnect
17. Remove screw to release main harness ground ring ter-
Harness
minal and brake line P-clamp from front of upper fork
bracket.
18. Pull main harness and both radio ground and harness
ground ring terminals through opening on right side of
fairing bracket allowing conduit and connectors to hang
over top of engine guard.
19. Pull ignition switch and handlebar switch control conduit
out through opening at top of fairing bracket.
20. Remove locknuts and bolts to release fairing bracket
Figure 2-171. Wrap Main Harness in Shop Towels
from holes at rear of steering head.
7.
Draw the main harness conduit, handlebar switch con-
INSTALLATION
trol conduit, radio ground wire and radio antenna cable
as far forward as possible. Rest the connectors of the
NOTE
longer harnesses on the front fender.
To install the fairing bracket, begin at step 1. If only the inner
fairing was removed, start at step 7.
8.
Remove left side of instrument nacelle. See INSTRU-
MENT NACELLE, REMOVAL, in this section, steps 1-6.
1.
Align holes in fairing bracket with those at rear of steer-
9.
See Figure
2-167. Disconnect instrument nacelle
ing head. Standing on right side, insert bolts until they
switches and ambient temperature sensor from intercon-
exit fairing bracket on left side of motorcycle. Install lock-
nect harness as follows:
nuts and tighten to 20-30 ft-lbs (27.1-40.7 Nm).
● Instrument nacelle switch connector [105], 12-place
2.
Route ignition switch and handlebar switch control con-
Multilock.
duit through opening at top of fairing bracket. See Figure
2-173.
● Ambient temperature sensor connector [107], 3-
place Multilock.
3.
Route main harness and both radio ground and harness
ground ring terminals through opening on right side of
10.
See Figure 2-167. Draw branches of interconnect har-
fairing bracket. See Figure 2-173.
ness (terminating in odometer reset switch and speed-
4.
Install screw to fasten harness ground ring terminal and
ometer, tachometer, indicator lamps, instrument nacelle
switch and ambient temperature sensor connectors)
brake line P-clamp to front of upper fork bracket.
from instrument nacelle through tunnel of fairing bracket
5.
Draw wire harnesses and conduit out tunnel of fairing
to front of inner fairing.
bracket and pull as far forward as possible. Tightly wrap
clean shop towels around all conduit and connectors
11.
Separate any branches of the interconnect harness that
and secure with masking tape. See Figure 2-171.
may be intermingled with the main harness conduit.
Allow the interconnect harness to hang along the left
6.
Install right side instrument nacelle. See INSTRUMENT
side of the front fender.
NACELLE, INSTALLATION, in this section, steps 8-9.
12.
Capturing all connectors, tightly wrap clean shop towels
7.
Place protective material on top of front fender to protect
around the main harness conduit, handlebar switch con-
paint from scratches or other damage. Rest inner fairing
trol conduit, radio ground wire and radio antenna cable,
(with attached radio bracket and interconnect harness)
and secure with masking tape. See Figure 2-171.
on front fender.
13.
Remove four locknuts to release radio bracket and inner
8.
Place inner fairing over four fairing bracket studs while
fairing from studs of fairing bracket. See Figure 2-172.
feeding end of harness bundle through opening beneath
radio. See Figure 2-172. Verify that sides of inner fairing
14.
Lift inner fairing (with attached radio bracket and inter-
are positioned outboard of both fairing supports
(on
connect harness) from fairing bracket studs and move to
engine guards).
bench area.
9.
Install four locknuts to secure radio bracket and inner
NOTE
fairing to fairing bracket studs. Tighten locknuts to 96-
To remove the fairing bracket, proceed with steps 15-20.
144 in-lbs (10.9-16.3 Nm).
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f2105x2x
Inner
Fairing
Outer Fairing
Hooks
Fairing
Stud
Bracket
Trim
Strip
Bolt
Locknut
Slot
Locknut
Radio
Opening
Bracket
Figure 2-172. Inner Fairing Assembly
10.
Draw the harness bundle as far forward as possible,
resting the end of the bundle on the front fender. See
f2231x2x
Left and Right
Figure 2-171.
Handlebar Controls
11.
Find branch of interconnect harness terminating in
odometer reset switch and speedometer, tachometer,
Ignition
indicator lamps, instrument nacelle switch and ambient
Switch
temperature sensor connectors. Feed connectors and
conduit from front of inner fairing through tunnel of fair-
ing bracket and then out through opening at top of fairing
bracket to instrument nacelle.
12.
See Figure 2-167. Connect instrument nacelle switches
and ambient temperature sensor to interconnect har-
ness as follows:
● Instrument nacelle switch connector [105], 12-place
Multilock.
● Ambient temperature sensor connector [107], 3-
place Multilock.
13.
Returning to front of inner fairing, remove shop towels
and masking tape from around the harness bundle. Sep-
arate radio ground and main harness, ignition switch and
Radio
handlebar switch control conduit.
Main
Ground
Harness
14.
See Figure 2-170. Connect handlebar switch controls to
interconnect harness. Connect radio ground. Proceed
Figure 2-173. Route Main Harness and Conduit
as follows:
Thru Fairing Bracket
● Left handlebar switch controls connector [24], 12-
place Deutsch (gray); T-stud on left side of radio
bracket.
● Radio ground; single spade and socket terminal;
● Right handlebar switch controls connector [22], 12-
below radio (left side).
place Deutsch (black); T-stud on left side of radio
15.
See Figure 2-170. Connect main harness to intercon-
bracket.
nect harness as follows:
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HOME
● Main to interconnect harness connector [1], 12-
INSTALLATION
place Deutsch (black); below radio (right side).
● Main to interconnect harness connector [2], 12-
1.
Place spring inside hinge inserting spring pin into clos-
place Deutsch (gray); below radio (right side).
est hole. With coil and one spring pin positioned inside
hinge, second spring pin is outside.
● Main to interconnect harness connector [15], 4-
place Packard (black); below radio (right side).
2.
Place hinge into position capturing free end of external
● Main to interconnect harness connector [156], 6-
spring pin between ribs molded into glove box door.
place Deutsch (gray); below radio (right side).
3.
Install plastic barrels to hold hinge in door. Slot in barrel
16. See Figure 2-170. Connect ignition switch to main har-
prevents interference with spring pin installed between
ness. Connect radio antenna cable. Proceed as follows:
ribs of door. Push barrels in until tight.
● Ignition switch connector
[33],
4-place Packard
NOTE
(black); inside fairing bracket tunnel (right side).
● Radio antenna cable connector [51]; back of radio
Install new glove box door bumpers in inner fairing if dam-
(left side).
aged or missing. Insert tail of rubber bumper into hole, and
moving to front of inner fairing, pull anchor through hole.
17. Orient connectors as shown in Figure 2-170. Install two
new cable straps outboard of radio bracket hooks to
4.
Place glove box door into position against inner fairing.
secure wire bundles and conduit to convoluted tubing of
Holding locknuts (with flat washers) at front of inner fair-
interconnect harness. Cut any excess cable strap mate-
ing, use a T25 TORX drive head to tighten hinge screws.
rial.
5.
To conceal glove door fasteners, snap screw cap cover
into place below hinge.
CAUTION
6.
Install the outer fairing. See OUTER FAIRING, INSTAL-
To avoid chafing wires of interconnect harness, verify
LATION, in this section.
that trim strips are installed inboard of hooks on radio
bracket.
18. Install the outer fairing. See OUTER FAIRING, INSTAL-
LATION, in this section.
19. Install left side of instrument nacelle. See INSTRUMENT
NACELLE, INSTALLATION, in this section, steps 5-7
and 9-10.
20. Install bezel. See BEZEL, INSTALLATION, in this sec-
tion.
GLOVE BOX DOOR/HINGE
REMOVAL
1.
Remove the outer fairing. See OUTER FAIRING,
REMOVAL, in this section.
2.
To access glove box door fasteners, pull out screw cap
cover below hinge.
3.
Holding locknuts at front of inner fairing, use a T25
TORX drive head to loosen hinge screws.
4. Hold glove box door closed as hinge screws are com-
pletely removed. If not held closed, door will pop open as
spring loaded hinge is released and door may be
dropped to the floor.
5. If hinge replacement is necessary, remove plastic bar-
rels to release hinge from door.
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WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S)
2.31
1.
Standing at the front of the motorcycle, carefully insert
WINDSHIELD REMOVAL
the windshield brackets between the headlamp nacelle
and the auxiliary lamp bracket. Lower the windshield into
1. See Figure 2-174. Standing at the front of the motorcy-
position until the lower notches on the windshield brack-
cle, use a finger to raise the wireform latch springs on
ets are seated on the lower grommets.
both sides of the windshield.
2.
Gently push the top of the windshield toward the rear
2. Gently pull on the top of the windshield until the upper
until the upper notches fully engage the upper grom-
notches on the windshield brackets are free of the upper
mets. See Figure 2-174.
grommets.
3.
Push down on the wireform latch springs, so that they
overhang the rubber grommets. If some adjustment is
3. Carefully raise the windshield until the lower notches are
necessary, loosen the retaining screws and rotate the
free of the lower grommets.
latch springs into the proper position.
4. Remove windshield from motorcycle.
NACELLE REMOVAL (FLHR/C)
WINDSHIELD INSTALLATION
1.
Remove the windshield. See WINDSHIELD REMOVAL
on this page.
CAUTION
2.
Remove the Phillips screw at the bottom of the head-
lamp door (chrome ring). Remove the headlamp door.
To avoid scratching headlamp nacelle or auxiliary lamp
bracket, be sure that all four notches on the windshield
3.
Remove the eight Phillips screws to free the headlamp
brackets are firmly seated on a rubber grommet.
housing from the headlamp nacelle.
Wireform
Headlamp
Latch Spring
Nacelle
Windshield
Clutch
Cable
Auxiliary Lamp
Bracket
Upper
Grommet
f2278x2x
Figure 2-174. Windshield (FLHR/C)
2005 Touring: Chassis
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10. Remove the grommets (and clutch cable clamp) from the
left and right side fork bracket studs.
Fork Lock
Plate
11. Raise the handlebar clamp shroud, and after separating
the halves of the headlamp nacelle slightly, slide the
Phillips
shroud forward running the shaft of the Phillips screw
Screw
down the gap. See Figure 2-176.
Handlebar
12. Reaching inside the headlamp nacelle, separate the pin
Clamp Shroud
and socket halves of the Accessory Switch and Auxiliary
Lamp Switch connectors.
13. Carefully separate the halves of the headlamp nacelle
and remove from motorcycle.
Headlamp
Chrome
Nacelle
Strip
Left Side
NACELLE INSTALLATION (FLHR/C)
Trim
Strip
1.
Fit halves of the headlamp nacelle together engaging
the holes in the nacelle with the left and right side fork
bracket studs.
Flange
2.
Reaching inside the headlamp nacelle, mate pin and
Nut
socket halves of the Accessory Switch and Auxiliary
Lamp Switch connectors.
Flat
3.
If disassembled, install screw assembly on the handle-
Washer
bar clamp shroud as shown in Figure 2-176.
4.
Part the halves of the headlamp nacelle slightly. With the
flat washer on the inboard side of the nacelle, slide the
Keps
shroud rearward running the shaft of the Phillips screw
Nut
down the gap. Position the shroud over the flange at the
top of the nacelle.
f2195x2x
5.
Mate the halves of the headlamp nacelle and tighten the
Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).
Figure 2-175. Headlamp Nacelle Assembly
6.
Install two Phillips screws to secure the handlebar clamp
shroud to the fork lock mechanism. Install the fork lock
plate.
4.
Squeeze the two external tabs (if present) to remove the
wire connector at the back of the headlamp bulb.
Remove the headlamp housing assembly from the
motorcycle.
5.
Reaching inside the headlamp nacelle, remove the
flange nut to release the chrome strip at the top of the
nacelle. See Figure 2-175.
6.
Carefully pry off the fork lock plate at the rear of the han-
dlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.
7.
Loosen the Phillips screw from tab at the front of the
handlebar clamp shroud (but do not remove).
8.
Remove the two acorn nuts from the left side fork
bracket studs. Remove acorn nuts from the right side
fork bracket studs.
Screw
Assembly
f1458b2x
9.
Cover the front fender with suitable material to protect
the fender paint. Remove the auxiliary lamp bracket from
Figure 2-176. Handlebar Clamp Shroud and Screw
the left and right side fork bracket studs and carefully set
Assembly
on front fender.
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2005 Touring: Chassis
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1WARNING
To avoid possible damage to the brake hose, throttle
cables and/or handlebar switch wires, verify that trim
strips are installed on inside edges of the headlamp
nacelle. Cutting or severe chafing of the brake hose,
throttle cables and/or handlebar switch wires could
cause loss of function while riding, possibly resulting in
death or serious injury.
7.
Verify that trim strips are installed on inside edges of
headlamp nacelle. Install new trim strips if cracked, bro-
ken or missing.
f2194x2x
8.
Inserting the weld stud on the chrome strip into the hole
at the top of the headlamp nacelle, reach inside the
Figure 2-177. Remove Screw From Slot in Wind Deflector
nacelle to install flange nut. Tighten flange nut to 15-20
in-lbs (1.7-2.3 Nm).
9.
Install the grommets on the left and right side fork studs.
Screw
Assembly
10.
Slide the auxiliary lamp bracket onto the left and right
side fork bracket studs. Verify that the four grommets are
in place on the inboard side of the auxiliary lamp brack-
ets.
11.
Install the acorn nuts on the fork bracket studs and
tighten to 72-108 in-lbs (8.1-12.2 Nm). Be sure to cap-
ture the clutch cable clamp on the upper left stud before
installing the acorn nut.
12.
Install the wire connector at the back of headlamp bulb.
13.
Align holes in headlamp housing with those in headlamp
nacelle (headlamp door bracket at bottom). Install the
f2193x2x
eight Phillips screws.
14.
Fit the square-shaped portion of the headlamp door
Figure 2-178. Handlebar Clamp Shroud/Wind Deflector
spring into the slot at the top of the headlamp housing
and Screw Assembly
and then snap the headlamp door (chrome ring) into
place. Install Phillips screw at the bottom of the head-
lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).
5.
Carefully pry off the fork lock plate at the rear of the han-
15.
Install the windshield. See WINDSHIELD INSTALLA-
TION in this section.
dlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.
6.
Loosen Phillips screw at front of wind deflector (but do
not remove). Reaching inside the headlamp nacelle,
NACELLE REMOVAL (FLHRS)
release screw head from slot in tab and then draw screw
assembly down and out through headlamp nacelle. See
1. Remove the Phillips screw at the bottom of the head-
Figure 2-177.
lamp door (chrome ring). Remove the headlamp door.
7.
Raise handlebar clamp shroud/wind deflector and
2. Remove the eight Phillips screws to free the headlamp
housing from the headlamp nacelle.
remove from motorcycle. See Figure 2-178.
3. Squeeze the two external tabs (if present) to remove the
NOTE
wire connector at the back of the headlamp bulb.
Remove the headlamp housing assembly from the
If damage requires separation of parts, remove three flange
motorcycle.
bolts to remove handlebar clamp shroud from wind deflector.
4. Reaching inside the headlamp nacelle, remove the
8.
Reaching inside the headlamp nacelle, separate the pin
flange nut to release the chrome strip at the top of the
and socket halves of the Accessory Switch connector.
nacelle.
2005 Touring: Chassis
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9.
Using a T-40 TORX drive head, remove the left side fork
11.
Install the wire connector at the back of headlamp bulb.
bracket bolts (with flat washers). Remove the right side
fork bracket bolts (with flat washers).
12.
Align holes in headlamp housing with those in headlamp
nacelle (headlamp door bracket at bottom). Install the
10. Carefully separate the halves of the headlamp nacelle
eight Phillips screws.
and remove from motorcycle.
13.
Fit the square-shaped portion of the headlamp door
spring into the slot at the top of the headlamp housing
and then snap the headlamp door (chrome ring) into
NACELLE INSTALLATION (FLHRS)
place. Install Phillips screw at the bottom of the head-
lamp door and tighten to 9-18 in-lbs (1.0-2.0 Nm).
1.
Fit halves of the headlamp nacelle together aligning the
holes in the nacelle with those in the upper and lower
fork brackets.
2.
Start right side fork bracket bolts (with flat washers).
Start left side fork bracket bolts (with flat washers). Be
sure to capture clutch cable clamp when installing upper
fork bracket bolt on left side of motorcycle (open side of
clamp faces forward).
3.
Using a T-40 TORX drive head, alternately tighten the
fork bracket bolts to 15-20 ft-lbs (20-27 Nm) in a cross-
wise pattern.
4.
Reaching inside the headlamp nacelle, mate pin and
socket halves of the Accessory Switch connector.
5.
Position the handlebar clamp shroud/wind deflector on
flange at top of headlamp nacelle.
NOTE
If separated, install three flange bolts to fasten handlebar
clamp shroud to wind deflector. Alternately tighten bolts to
12-18 ft-lbs (16.3-24.4 Nm).
6.
If disassembled, assemble screw assembly as shown in
Figure 2-178.
7.
Holding screw assembly, reach inside headlamp nacelle
and insert head of Phillips screw up through opening to
engage slot in tab at front of wind deflector. See Figure
2-177. Tighten screw to 10-20 in-lbs (1.1-2.3 Nm).
8.
Install two Phillips screws to secure the handlebar clamp
shroud to the fork lock mechanism. Install the fork lock
plate.
1WARNING
To avoid possible damage to the brake hose, throttle
cables and/or handlebar switch wires, verify that trim
strips are installed on inside edges of the headlamp
nacelle. Cutting or severe chafing of the brake hose,
throttle cables and/or handlebar switch wires could
cause loss of function while riding, possibly resulting in
death or serious injury.
9. Verify that trim strips are installed on inside edges of
headlamp nacelle. Install new trim strips if cracked, bro-
ken or missing.
10. Inserting the weld stud on the chrome strip into the hole
at the top of the headlamp nacelle, reach inside the
nacelle to install flange nut. Tighten flange nut to 15-20
in-lbs (1.7-2.3 Nm).
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FRONT FENDER
2.32
REMOVAL
Front Fender Tip Lamp [32]
NOTE
If fender tip lamp is absent, start procedure at step 5.
1.
FLHT/C/U: Reaching in below the fairing cap on the left
side of the steering head, locate the front fender tip lamp
connector (black 2-place Multilock). See Figure 2-179.
Remove the outer fairing only if necessary. See Section
2.29 UPPER FAIRING/WINDSHIELD
(FLHT/C/U),
OUTER FAIRING/WINDSHIELD, REMOVAL.
FLHR: Remove the Phillips screw at the bottom of the
headlamp door (chrome ring). Remove the headlamp
door. Remove the eight Phillips screws to free the head-
lamp housing from the headlamp nacelle. Squeeze the
two external tabs to remove the wire connector at the
back of the headlamp bulb. Remove the headlamp hous-
ing assembly from the vehicle. Locate the front fender tip
f2238x8x
lamp connector (black 2-place Multilock). See Figure 2-
180.
Figure 2-179. Inner Fairing (FLHT/C/U)
2.
Depress the button on the socket terminal side of the
connector and pull apart the pin and socket halves.
3.
Draw socket connector down to fender area.
4.
Carefully cut cable strap to release front fender tip lamp
wires from brake line hose.
5.
Place the motorcycle on a hydraulic center stand with
the front wheel raised off the ground.
6.
Use shop rag or tape to protect fender area adjacent to
caliper, as incidental contact can occur during caliper
removal.
7.
Remove both the upper and lower mounting bolts from
lugs of front fork leg to release brake caliper assembly.
Lift caliper upward to remove from brake disc. Using thru
hole, cable strap caliper to rail of engine guard. Repeat
step to release caliper on opposite side of wheel.
Front Fender
NOTE
Tip Lamp [32]
Do not operate the front brake hand lever with the front wheel
f2212x8x
Used on FLHR Only
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the caliper.
Figure 2-180. Headlamp Nacelle (FLHRC)
8. Insert screwdriver or steel rod through hole in axle on
right side of vehicle. While holding axle stationary,
remove the axle nut, lockwasher and flat washer on the
left side.
10. With soft mallet, tap axle toward right side of vehicle until
9. Loosen the two axle holder nuts at bottom of right side
loose. Pull axle from hub while supporting wheel.
fork leg.
Remove wheel.
2005 Touring: Chassis
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11. Bend tabs on lockplates away from flats of four fender
11.
Remove drill bit from axle hole.
mounting bolts. Remove fender mounting bolts and lock-
12.
Install brake caliper as follows:
plates. Remove fender from vehicle.
a. Use shop rag or tape to protect fender area adja-
cent to caliper, as incidental contact can occur dur-
ing caliper installation.
INSTALLATION
b. With the bleeder valve topside, position caliper so
that brake disc is situated between friction pads.
Now align upper mounting hole in caliper with upper
NOTE
mounting lug on fork leg.
If fender tip lamp is absent, perform steps 1 and 3-12.
c. Loosely install long caliper mounting bolt into upper
lug of front fork leg.
1. Align mounting holes in fender and lockplates with those
in fork tubes. Install four fender mounting bolts and
d. Install short caliper mounting bolt into lower lug of
front fork leg. Tighten lower mounting bolt to 28-38
tighten to 16-20 ft-lbs (22-27 Nm). Bend tabs on lock-
plates against flats of fender mounting bolts.
ft-lbs (37.9-51.5 Nm).
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
2. Route socket housing of front fender tip lamp connector
(37.9-51.5 Nm).
upward behind chrome skirt (FLHT/C/U) or through bot-
tom of headlamp nacelle (FLHR) to area beneath upper
f.
Repeat step 12 to install caliper on opposite side of
fork bracket. Mate pin and socket halves.
wheel.
NOTE
13.
Install new cable strap to secure front fender tip lamp
To connect front fender tip lamp with the outer fairing
wires to brake line hose. Cut any excess cable strap
installed (FLHT/C/U models), reach in below the fairing cap
material.
on the left side of the steering head.
14.
FLHT/C/U: Install the outer fairing, if removed. See Sec-
tion 2.29 UPPER FAIRING/WINDSHIELD (FLHT/C/U),
3. Place wheel into position between forks with the valve
OUTER FAIRING/WINDSHIELD, INSTALLATION.
stem on the right side of the vehicle.
FLHR: Install wire connector at the back of the head-
4. Coat the axle with ANTI-SEIZE LUBRICANT.
lamp bulb. Align holes in headlamp housing with those in
headlamp nacelle. Install eight Phillips screws. Install
5. Supporting wheel, insert threaded end of axle through
the headlamp door
(chrome ring) and door screw.
right fork leg. Push axle through fork, short external
Tighten screw to 9-18 in-lbs (1.0-2.0 Nm).
spacer and wheel hub until it begins to emerge from left
side.
6. With the three notches on the bearing side, push axle
through long external spacer and left fork leg until axle
shoulder contacts external spacer on right fork side.
7.
Install flat washer, lockwasher and axle nut.
8.
Insert screwdriver or steel rod through hole in axle on
right side of vehicle. While holding axle stationary,
tighten axle nut to 50-55 ft-lbs (68-75 Nm).
9.
Insert 7/16 inch drill bit into hole in axle.
10. Pull fork leg so that it just contacts drill bit, and then
tighten axle holder nuts to 132-180 in-lbs (14.9-20.3
Nm).
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2005 Touring: Chassis
HOME
REAR FENDER
2.33
REMOVAL
f2279x2x
T40 TORX
Bolt
1.
Place the motorcycle on a hydraulic center stand with
the rear wheel raised off the ground.
2.
Remove seat. See Section 2.24 SEAT, REMOVAL.
3.
Remove rear wheel. See Section 2.4 REAR WHEEL,
REMOVAL.
4.
Disconnect the rear fender lights connector anchored at
the front of the rear fender. Depress the button on the
socket terminal side and pull apart the pin and socket
halves. Release anchor from fender hole. See Figure 2-
181.
5.
Gently pull side cover from frame downtube (no tools
required). Repeat step on opposite side of vehicle.
6.
Remove four screws (two on FLHR/C/S and FLTR) to
release license plate bracket from luggage rack.
Figure 2-182. Rear Fender Front Mounting Bolt
(Left Side View)
7.
Standing on left side of vehicle, use a T40 TORX drive
head to release front of rear fender from battery box.
See Figure 2-182.
9.
Reaching under bumper, remove nut (with flat washer) to
free bumper bracket from weld stud on fender. Remove
8.
At rear of vehicle, remove inside bolt (and flange nut) to
bumper from vehicle.
release rear bumper support rail from saddlebag support
bracket and saddlebag support rail. Repeat step on
10.
Using a T40 TORX drive head, remove fender side
opposite side of vehicle. See Figure 2-183.
mounting bolt located just below side cover grommet.
Repeat step on opposite side of vehicle. See Figure 2-
184.
11.
Using a T40 TORX drive head, remove upper rear bolt
f2013x8x
from saddlebag support bracket. Repeat step on oppo-
Rear Fender
site side of vehicle. See Figure 2-185.
Lights Connector [7]
T40 TORX Bolt
f1908x2x
Figure 2-181. Rear Fender (Top View)
Figure 2-183. Release Bumper From Saddlebag Rail
2005 Touring: Chassis
2-147
HOME
T40
T40
LEFT SIDE
T40
TORX Bolt
TORX Bolt
Saddlebag
TORX Bolt
Front
Rear
Support Bracket
f1862x2x
f1864x2x
f1991x2x
Figure 2-185. Saddlebag Support Bracket Bolts
RIGHT SIDE
(Left Side View)
T40
TORX Bolt
INSTALLATION
1.
Exercising caution to avoid scratching fender paint on
luggage rack or other bracketry, carefully roll the fender
in. See Figure 2-186. If necessary, have one person
spread the saddlebag support brackets while the other
rolls the fender in.
2.
Engaging hole of fender rear spacer nut, use a T40
TORX drive head to start upper front bolt in saddlebag
support bracket. Repeat step on opposite side of vehi-
cle. See Figure 2-185.
3.
Start upper rear bolt in saddlebag support bracket.
Repeat step on opposite side of vehicle.
4.
Standing on left side of vehicle, start bolt securing front
Figure 2-184. Rear Fender Side Mounting Bolts
of rear fender to battery box. See Figure 2-182.
5.
Engaging hole in frame and fender front spacer nut, start
fender side mounting bolt located just below side cover
12.
Remove upper front bolt from saddlebag support
grommet. Repeat step on opposite side of vehicle. See
bracket. Repeat step on opposite side of vehicle. Be
Figure 2-184.
aware that rear fender will drop when the forward bolts
are removed.
6.
Reaching under rear fender, hang bumper bracket on
fender weld stud. Install flat washer and start nut on
13.
Exercising caution to avoid scratching fender paint on
luggage rack or other bracketry, carefully roll the fender
stud.
out. See Figure 2-186. If necessary, have one person
7.
Start inside bolt (with flange nut) to fasten rear bumper
spread the saddlebag support brackets while the fender
support rail to saddlebag support bracket and saddle-
is rolled out.
bag support rail. Repeat step on opposite side of vehi-
cle. See Figure 2-183.
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2005 Touring: Chassis
HOME
NOTE
Dental floss can be used to gently saw the heated cloisonne
free of the rear fender.
4.
Remove remaining adhesive with 3M GENERAL PUR-
POSE ADHESIVE REMOVER (Part No. 051135).
Installation
1.
Peel paper backing off cloisonne.
2.
Place cloisonne in position over recess in rear fender.
NOTE
f2014x2x
The cloisonne is centered left to right over the dimpled
recess in the rear fender with the bottom edge of the cloi-
sonne 1.75 inches (44.45 mm) above the bottom edge of the
Figure 2-186. Carefully Roll Out Rear Fender
fender.
3.
Press firmly to affix cloisonne.
8.
Alternately tighten all rear fender T40 TORX bolts to 15-
20 ft-lbs (20-27 Nm). Tighten nut on fender weld stud to
secure bumper bracket.
9740
FLHRS
9.
Install four screws
(two on FLHR/C/S and FLTR) to
secure license plate bracket to luggage rack.
10.
Mate pin and socket halves of rear fender lights connec-
tor and snap anchor in rear fender hole. See Figure 2-
181.
11.
Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place
(no tools
required). Repeat step on opposite side of vehicle.
12.
Install rear wheel. See Section
2.4 REAR WHEEL,
INSTALLATION.
13.
Install seat. See Section 2.24 SEAT, INSTALLATION.
9741
FLTR
REAR FENDER CLOISONNE
Removal
1. Apply 3M GENERAL PURPOSE ADHESIVE REMOVER
(Part No. 051135) to edge of adhesive backing visible
behind cloisonne. Allow to soak.
CAUTION
Avoid excess heat which will damage the painted sur-
face.
Figure 2-187. Rear Fender Cloisonne
2. Carefully apply heat directly onto cloisonne with ROBIN-
AIR HEAT GUN (HD-25070).
3. Lift the cloisonne from fender.
2005 Touring: Chassis
2-149
HOME
JIFFY STAND
2.34
GENERAL
The vehicle is equipped with a jiffy stand (or side stand) that
locks when placed in the full forward position (down) with the
full weight of the vehicle resting on it.
1WARNING
Leg Stop
Without the full weight of the motorcycle resting on the
Longer Side
jiffy stand, any vehicle movement can cause the jiffy
Faces Rear
stand to retract slightly from the full forward position. If
Bracket
the jiffy stand is not in the full forward or lock position
when the full vehicle weight is rested on it, the vehicle
could fall over, which could result in death or serious
Flange
Nut
injury.
1WARNING
Always park the vehicle on a firm, level surface. The
weight of the vehicle can cause it to fall over, which
FRONT
REAR
could result in death or serious injury.
1WARNING
Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted during vehicle operation,
unexpected contact with the road surface can distract
the rider. While the jiffy stand will retract upon contact,
f1142a2x
the momentary disturbance and/or rider distraction can
lead to loss of vehicle control resulting in death or seri-
ous injury.
Figure 2-189. Leg Stop Orientation
(Full Forward Position)
REMOVAL
Frame
1WARNING
Hole
Securely block vehicle under frame to be sure that vehi-
Flange
Nut
cle will not fall when jiffy stand is removed. Inadequate
safety precautions could result in death or serious
Leg Stop
injury.
Lockwasher
1.
Block motorcycle under frame, so that vehicle is securely
upright and level. Jiffy stand should be able to move
Bolt
through its full range of travel without the weight of the
vehicle resting on it.
Bracket
Rubber
2.
See Figure 2-188. Move jiffy stand to the retracted posi-
Stop
tion (up). Remove flange nut and leg stop from threaded
end of jiffy stand leg.
Spring
3.
Move jiffy stand to the full forward position
(down).
Jiffy
Stand
Grasping end of spring as close to frame tube as possi-
f1852x2x
ble, twist and turn end with needle nose pliers to unhook
Figure 2-188. Jiffy Stand Assembly
from frame hole. Remove jiffy stand leg from bracket.
2-150
2005 Touring: Chassis
HOME
4. Inspect jiffy stand assembly for worn or damaged parts.
Replace parts as necessary.
7846
INSTALLATION
1. Lubricate the jiffy stand leg with Loctite Aerosol Anti-
Seize Lubricant. Restrict the application to the area of
the jiffy stand leg that rotates within the bracket.
2. Insert threaded end of jiffy stand up through bottom of
bracket. With jiffy stand in the full forward position, par-
tially place spring end into frame hole. Rap spring with a
Rubber
rubber mallet to fully seat in hole.
Stop
NOTE
Verify that opposite end of spring enters hole at front of leg
weldment. If end enters hole from rear, spring coil will rub on
Figure 2-190. Jiffy Stand
leg when jiffy stand is exercised.
3. Holding jiffy stand at the full forward position, install leg
5.
Extend and retract jiffy stand leg several times to verify
stop over threaded end with the stamped “side down.”
proper operation. Jiffy stand should swing freely to the
Install flange nut and tighten to 43-53 ft-lbs (58-72 Nm).
fully extended and fully retracted positions.
6.
Move jiffy stand to the full forward position. Carefully
1WARNING
remove support blocking from beneath motorcycle frame
and rest motorcycle on jiffy stand.
If leg stop is installed incorrectly, excess wear may
cause the vehicle to fall over when rested on the jiffy
stand, which could result in death or serious injury.
CAUTION
4.
Verify that the longer side of the leg stop faces the rear
Verify that rubber stop is in place on prong of jiffy stand.
of the vehicle. See Figure 2-189.
Without the rubber stop, the stand will make hard con-
tact with the lower frame tube when retracted, possibly
resulting in chipping or nicking of the powder coat.
Replace rubber stop if torn or deteriorated. See Figure 2-
190.
2005 Touring: Chassis
2-151
HOME
FOOTBOARDS/FOOTRESTS
2.35
c. Tighten front bracket socket screw to 30-35 ft-lbs
RIDER FOOTBOARD
(41-48 Nm).
d. Alternately tighten rear bracket hex bolts to 15-20 ft-
REMOVAL
lbs (20-27 Nm).
1.
Remove right side footboard and bracket assembly as
follows:
a. Remove two allen head socket screws (with lock
DISASSEMBLY
washers and flat washers) to release footboard
brackets from frame weldment. See Figure 2-191.
NOTE
For best results, approach from left side of motorcy-
cle using a 3/8 inch ball allen with extension.
If only replacing the rubber pad, refer to step 1 below and
then see steps 4-5 under ASSEMBLY.
2.
Remove left side footboard and bracket assembly as fol-
lows:
1.
Tilt footboard upward. From bottom of footboard, use a
large flat blade screwdriver to push four rubber anchors
a. Raise the motorcycle on a hydraulic center stand so
that the weight of the motorcycle is not resting on
on pad up through holes in footboard.
the jiffy stand.
2.
Remove nuts from pivot bolts at underside of footboard.
b. Remove socket screw (with lockwasher and flat
3.
Remove pivot bolts to release footboard from brackets.
washer) to release footboard forward bracket from
frame weldment. See Figure 2-191. For best results,
4.
Remove footboard brackets. See REMOVAL.
approach from opposite side of motorcycle using a
3/8 inch ball allen with extension.
c. To free footboard rear bracket from frame weldment
and jiffy stand bracket, remove lower hex bolt (with
ASSEMBLY
lockwasher) and upper hex bolt (with lockwasher
and locknut).
1.
Install footboard brackets. See INSTALLATION.
2.
Place footboard into position between brackets and
install pivot bolts so that the nuts will be on the inboard
INSTALLATION
side.
1.
Install right side footboard and bracket assembly as fol-
NOTE
lows:
a. Insert two allen head socket screws (with lockwash-
The bottom of FLHRS footboards are stamped L(eft) or
ers and flat washers) through frame weldment into
R(ight) to ensure proper installation.
footboard brackets. See Figure
2-191. For best
results, approach from left side of motorcycle using
3.
Install nuts onto pivot bolts and alternately tighten to 84-
108 in-lbs (9.5-12.2 Nm).
a 3/8 inch ball allen with extension.
b. Alternately tighten socket screws to 30-35 ft-lbs (41-
4.
Moisten four rubber anchors on new pad with soapy
48 Nm).
water.
2.
Install left side footboard and bracket assembly as fol-
5.
Place pad into position on footboard. From bottom of
lows:
footboard, use pliers to pull rubber anchors down
through holes in footboard.
a. Insert allen head socket screw (with lockwasher and
flat washer) through frame weldment into footboard
forward bracket. See Figure 2-191. For best results,
approach from opposite side of motorcycle using a
PASSENGER FOOTBOARD
3/8 inch ball allen with extension.
b. At footboard rear bracket, slide upper hex bolt
through frame weldment, jiffy stand bracket and
REMOVAL
footboard bracket thru hole. Install lockwasher and
locknut. Slide lower hex bolt through frame weld-
1.
Remove socket screw with lockwasher to remove foot-
ment and jiffy stand bracket into threaded hole of
board bracket from rear swingarm bracket.
footboard bracket.
2-152
2005 Touring: Chassis
HOME
1
ALL MODELS
Except FLHRS
1
2
2
8
7
9
4
10
11
12
12
11
3
6
13
5
10
7
Left Side
6
14
Right Side
1
1
2
FLHRS
9
8
12
7
4
11
2
10
10
11
6
12
3
5
7
6
13
10
1.
Rubber Pad (2)
8.
Nut
11
2.
Footboard (2)
9.
Left Front Bracket
12
3.
Pivot Bolt (4)
10.
Socket Screw (3)
14
4.
Pivot Bolt Nut (4)
11.
Lockwasher (3)
5.
Left Rear Bracket
12.
Flat Washer (3)
6.
Hex Bolt (2)
13.
Right Front Bracket
7.
Lockwasher (2)
14.
Right Rear Bracket
Figure 2-191. Rider Footboards
INSTALLATION
NOTE
Passenger footboards can be adjusted to one of three posi-
1. Insert pin on footboard bracket into hole in rear swing-
tions. To move footboards to a new position, remove plastic
arm bracket.
plugs from holes in rear swingarm bracket as necessary.
2005 Touring: Chassis
2-153
HOME
3. Place footboard into position on bracket and install pivot
pins from the outboard side. Using a brass drift and rub-
f2241x2x
1
ber mallet, tap pins until centered in lugs of bracket.
4. Moisten rubber beads on new pad with soapy water.
8
Place pad into position on footboard. From bottom of
7
footboard, use needle nose pliers to pull rubber beads
down through holes in footboard.
5
5. Engage nubs on inboard corners of pad with holes in
6
footboard.
3
4
2
PASSENGER FOOTREST (FLHRS)
3
REMOVAL
1.
Remove socket screw with lockwasher to remove foot-
1.
Rubber Pad
5. Steel Ball
rest bracket from rear swingarm bracket.
2.
Footboard
6. Spring
3.
Pivot Pin (2)
7. Socket Screw
4.
Footboard Bracket
8. Lockwasher
INSTALLATION
Figure 2-192. Passenger Footboard
1.
Insert pin on footrest bracket into hole in rear swingarm
(All Models Except FLHRS)
bracket.
NOTE
2.
Install socket screw with lockwasher. Tighten socket
Passenger footrests can be adjusted to one of three posi-
screw to 15-18 ft-lbs (20-24 Nm).
tions. To move footrests to a new position, remove plastic
plugs from holes in rear swingarm bracket as necessary.
DISASSEMBLY
2.
Install socket screw with lockwasher. Tighten socket
screw to 15-18 ft-lbs (20-24 Nm).
NOTE
If only replacing the rubber pad, refer to step 1 below and
then see steps 4-5 under ASSEMBLY.
DISASSEMBLY
1. Tilt footboard upward. From bottom of footboard, use a
small flat blade screwdriver to push rubber beads on pad
NOTE
up through holes in footboard. Remove pad. See Figure
2-192.
If only replacing the rubber pad, refer to step 1 below and
then see steps 7-9 under ASSEMBLY.
2. Using a brass drift and rubber mallet, tap two pivot pins
toward center of footboard and remove.
1. Remove socket screw from end of footrest. Remove rub-
3. Remove footboard from footboard bracket.
ber pad from footrest. See Figure 2-193.
4. Remove steel ball and spring from hole in footboard
2. Remove footrest from footrest mount.
bracket.
5. Remove footboard bracket from rear swingarm bracket.
3. Remove retaining ring from groove at end of pivot pin.
See REMOVAL.
Remove pivot pin.
4. Remove footrest mount and wave spring from footrest
bracket.
ASSEMBLY
5. Remove footrest bracket from rear swingarm bracket.
1.
Install footboard bracket. See INSTALLATION.
See REMOVAL.
2.
Place spring into hole in footboard bracket. Place ball on
top of spring. See Figure 2-192.
2-154
2005 Touring: Chassis
HOME
4.
Install pivot pin into top hole in footrest bracket. Top hole
is countersunk so that head of pivot pin is flush after
10
f2290x2x
installation.
9
NOTE
8
Verify operation of footrest mount before installing retaining
ring. The ease with which the footrest mount pivots is based
5
on the curvature of the wave spring. Flattening the wave
6
spring allows the footrest mount to move more easily, while
2
increasing the curvature makes movement more difficult.
4
5.
Install new retaining ring in groove at end of pivot pin.
3
1
6.
Slide footrest onto footrest mount.
7
7.
Place rubber pad into footrest.
8.
Apply a small dab of Loctite Medium Strength Thread-
1. Socket Screw
6. Footrest Mount
locker 243 (blue) to threads of socket screw.
2. Rubber Pad
7. Wave Spring
9.
Start socket screw into end of footrest. Rotate footrest so
3. Footrest
8. Footrest Bracket
that the rubber pad is topside and tighten socket screw
4. Retaining Ring
9. Socket Screw
to 15-20 ft-lbs (20-27 Nm).
5. Pivot Pin
10. Lockwasher
Figure 2-193. Passenger Footrest (FLHRS)
ASSEMBLY
1. Install footrest bracket. See INSTALLATION.
2. Align hole in wave spring with bottom hole in footrest
bracket. See Figure 2-193. Be sure that the concave
side is down and the flat edge is against the inboard side
of the footrest bracket.
3. Holding wave spring in place, install footrest mount
between arms of bracket with the rounded side of the
pivot pin end up.
2005 Touring: Chassis
2-155
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